WO2022096224A1

WO2022096224A1 - Automotive floor part with integrated heating device

Info

Publication number: WO2022096224A1
Application number: PCT/EP2021/077914
Authority: WO
Inventors: Edward Bendell; Raphael Merrien
Original assignee: Autoneum Management Ag
Priority date: 2020-11-03
Filing date: 2021-10-08
Publication date: 2022-05-12
Also published as: DE112021005804T5

Abstract

Automotive floor part with integrated heating device comprising a main floor part comprising at least a backing layer, a facing layer and a heating element, whereby the heating element is between the facing layer and the air permeable layer and materially connected to the adjacent layers, and further comprising means-for-connecting the heating element to a power supply, characterised that at least part of the layer or layers of the main floor part are extended to form a tail part comprising the means-for-connecting.

Description

Automotive floor part with integrated heating device

Technical Field

[0001] The present invention generally relates to an automotive floor part with an integrated heating device and a method for producing such a floor part

Background Art

[0002] Cars and passenger vehicles based on petrol/diesel engines are in general heated by using the heat coming from the powertrain and/or motor, generated during combustion of the fuel. In electric and hybrid-electric cars, this source of heat is no longer fully available. Hence, the vehicle is heated by the same electricity that the car needs for its driving range.

[0003] Traditionally the passenger compartment of a car is heated by an HVAC system; heated air is blown into the passenger compartment. This is a very ineffective way of transporting heat to the passengers. The passenger comfort may only be achieved after a long time, while heating up not only the direct surroundings of the passengers, but also the full air volume and the surrounding car parts of the passenger compartment. For an electric vehicle, this would mean that there is a loss of energy, in particularly at the beginning of a drive in an environment with low ambient temperatures. While at the same time, the passenger may be in discomfort. For this reason, electrical surface heating may be seen to be attractive.

[0004] Additionally in other situations in a car an alternative way of heating might be an advantage, for instance to keep certain areas like the battery or the storage area at a temperature above a certain temperature.

[0005] Although heated floor mats may be known, they are not commonly used. In addition, heat-radiating panels are disclosed in the literature but hardly seen on vehicles on the road. Furthermore, post integration of floor parts with a heating element, in particular with the on-board wire harness, is costly and cumbersome. Therefore post integration of such heating devices is mainly done via the cigarette lighter, however the current is limited for providing higher power for either larger, or faster warming heaters. In addition, loose cables and connectors or cables that can break are a hazard. Not only for tripping, or entangling, but they may be responsible for a power short cut or form a fire hazard.

[0006] In the past, attempts have been made to eliminate the loose cable by integrating connectors into the floor mat and the main flooring part. For instance, DE102015203706 discloses a push button type connector that connects the lower surface of the mat with the main floor part underneath. For the disclosed solution both - the floor mat and the main flooring part - need wiring and connectors integrated, increasing the overall cost and process steps. The connection is under the floor mat flush with the main floor part, and as both the connector and receiver are substantially horizontally orientated, the risk of soiling and/or water damage increases the risk of failure of the connection. Furthermore retrofitting of a vehicle later on is expensive and near to impossible with this system.

[0007]

[0008] The objective of the present invention is to provide an automotive floor part with an integrated heating device and a method for producing such a floor part, without the disadvantages of the state of art and more particular an automotive floor part with an integrated heating device that is optimised in the production and straightforward to fit or retrofit into the vehicle, like for instance an electric vehicle or a hybrid electric vehicle.

Summary of invention

[0009] The object is achieved by an automotive floor part with integrated heating device according to claim 1.

[0010] In particular, by an automotive floor part with integrated heating device comprising a main floor part comprising at least a backing layer, a facing layer and a heating element, whereby the heating element is between the facing layer and the air permeable layer and materially connected to the adjacent layers, and further comprising means-for-connecting the heating element to a power supply, characterised in that the means-for-connecting are arranged in a tail formed by at least part of the materials of the main floor part. [0011] With the materials of the main floor part are meant at least one of the backing layer and or facing layer and or additional layers, but not the heating element. However, part of the heating element might be located within the tail.

[0012] Surprisingly, the inventive connection zone may be used with all types of connectors or cables and may be adapted to local needs, as shown in preferred embodiments. It may be used to connect the floor part direct to the power supply and/or control unit, or indirect via adjacent floor part or parts with a similar connection zone. Advantageously, by using a tail for the means for connecting it is possible to raise the connecting zone away from the predominantly horizontal flooring surface, taking it out of the zone that is prone to water, snow, dust and dirt from the passenger feet.

[0013] The tail might be just as small as the means-for-connecting or might be over most of the width of the floor mat for instance that is fits just between the seat rails.

[0014] By using a tail on the floor mat the area with the means-for-connecting might be raised to an almost vertical position for instance underneath the seats where it can reach a possible power supply. The heating device might be connected to its own power supply or combined with a power supply for an optional seat heater. The power supply and/or the control of the optional seat heater and the floor mat heating device might be shared.

[0015]

[0016] By “means-for-connecting”, all components are meant that connect and/or control the power supply to the heating element. In its simplest form, the means-for-connecting is a power cable with a plug or connector that is able to connect the heating element to a power supply or an adjacent floor part. However, the means of connecting might also include at least one male or female connector part, or a magnetic connecting pair, preferably at least one connector part is connected with the heating element within the periphery of the floor part. Either it is enclosed between the porous layer and the facing layer, or it is placed in a cut-out such that it is within the boundaries’ of the periphery of the tail area of the floor part, optionally preferably after the application of an engulfing resin. [0017] The means might also include other electrical components necessary for the controlling and/or sensors needed to control the power and/or current to the heating element. It might also include wireless controlling units to control the heating element with use of a wireless controller. In an alternative solution, the means-for-connecting are able to connect to a second floor part for either a combined power supply and/or controlling of the temperature.

[0018]

[0019] The automotive floor part with integrated heating device according to the main claim comprises at least a backing layer, a facing layer and a planar heating element, whereby the heating element is between the facing layer and the backing layer and materially connected to the adjacent layers.

[0020]

[0021] The heating element is preferably a resistive heater based on a resistance element, preferably the heating element is at least one of a metal based element for instance a metal wire, ribbon or an etched or printed metal circuit, or a carbon based element, for instance a carbon printed circuit, coated thread or carbon yarn or a combination of carbon and metal elements.

[0022] For ease of handling, the heating element might be attached to or integrated in a carrier layer like a textile, for instance a woven fabric, a nonwoven, a foil or a film. The heating element might be attached to or integrated in the carrier layer by stitching, knitting, or gluing to the material, or might be interwoven as part of the fabric. Alternatively, the heating element might be printed on the carrier material or directly on the fibrous layer or the surface layer. Preferably, the carrier layer is a thin material layer that does not interfere with the overall function of the part; however, the main function of the carrier is to maintain the dedicated position of the heating element during the production of the floor part. The carrier layer might disintegrate during the production process of the floor part, for instance it might melt and connect to the adjacent layers.

[0023] Preferably, the heating element is formed in a grid type layout of multiple parallel heating wires or in the form of a serpentine. The heating element might be formed of at least one circuit, however it might also be formed of multiple circuits, that may have means-for-connecting each separate or combined. For instance, multiple circuits might be having an intertwined layout such that if one circuit fails the other or others will still cover the full surface. An alternative way of using multiple circuits is having dedicated areas that can be heated independent of each other to obtain a more flexible heating effect, whereby areas can be started or stopped heating depending on the needs of the passenger or depending on sensors.

[0024] Preferably a heating element comprises at least one circuit in the form of a wire embroidered on separate material, like a nonwoven, textile or fabric or alternatively is embroidered directly to air permeable fibrous material.

[0025] Alternatively, a heating element comprises at least one circuit in the form of a heating grid woven within a fabric.

[0026]

[0027] To prevent damage to the area where the means for connecting are exiting the tail part, the area might be protected with either a covering clip and/or at least part of the means-for-connecting and at least part of the material of the adjacent layer or layers may be engulfed with a resin such that the means-for-connecting are at least partly encapsulated in the resin and materially connected to the adjacent layers, the resin forming a solid connection between the adjacent layers and the means-for-connecting.

[0028]

[0029] Surprisingly, by clasping or engulfing in a resin both the means-for-connecting and the adjacent layers, it is possible to create a simple connector solution that is robust and prevents any damage to the connecting area and/or cables. In particular, pulling and bending of the area containing electrical appliances will be eliminated, and the durability will be increased. In addition by combining it with a tail area it is possible to position the connecting area out of the flooring area where is would have been more exposed to water, dust and impacts.

[0030] Preferably, a clasp is used to clamp around the exit area of the means-for-connecting. The clasp might be at least a two part device with an optional hinge connecting the two parts, which can clamp around the exit area, each part on one surface of the tail.

[0031] The clasp might have means for connecting both parts of the clasp through the material of the tail, like pins, hooks or male-female connecting areas to connect both parts together tightly. Preferably, the connection is irreversible to obtain a tamper proof sealing of the exit area. Preferably, the parts are designed such that they form a sealed, preferably watertight area around the exit of the means for connecting.

[0032] Alternatively and preferably, both the means-for-connecting and the adjacent layers are engulfed in a resin material. Preferably, a resin for the engulfing is used that is able to penetrate and bind to the adjacent fibrous layers as well as to the surface of the different means-for-connecting, for instance wires and/or connector plugs and/or connecting areas between the wires and the connector plugs.

[0033] The engulfing resin or the parts of the clasp can be either a thermoset or thermoplastic material; preferably, pronounced elastic properties are inherent in the material. For instance a thermoset material is used chosen from an epoxy or phenolic or polyurethane based material, a silicon based material or a synthetic or natural rubber material.

[0034] Preferably, the resin or the parts of the clasp comprises a polymer or copolymer selected from the group consisting of polyolefin, like polyethylene (PE) or polypropylene (PP) or ethylene propylene diene monomer (EPDM) or ethylene-octene (EO), polyester or thermoplastic elastomer of polyester (TPE-E), polyamide (PA) or thermoplastic elastomer of polyamide (TPE-A), polyoxymethylene POM, acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), Santoprene (TPV), styrene-butadiene copolymers (e.g. SBS), thermoplastic polyurethane (TPU), or a combination of these polymers.

[0035] In one embodiment, the resin material might be based on a hot melt solution, preferably a thermoplastic resin. Preferably the hot melt solution is based on a polymer or copolymer of one of polyester, like polyethylene terephthalate (PET), polyolefin, like polypropylene (PP) or polyethylene (PE), poly lactic acid (PLA), polyamide, like polyamide 6 (PA6) or polyamide 6,6 (PA6,6) or mixtures thereof.

[0036]

[0037] Preferably the resin material or the parts of the clasp further comprises a filler, preferably a fibrous filler, like glass fibers or carbon fibers, or an inert filler, like mica, carbon black or an inorganic filler like Barium Sulphate or Calcium carbonate or silica.

[0038] Preferably, the resin material or parts of the clasp are further comprising any of a dye, additives and/or process enhancers.

[0039] In general all material used for the floor part may be from a virgin, reclaimed and/ or recycled source.

[0040]

[0041] The backing layer can be any type of felt, foam or textile material.

[0042] Preferably, the backing layer is at least a fibrous layer for instance one of an air laid mat or a carded, cross-lapped mat. Eventually the mat might be needled to enhance the stiffness of the part and to obtain a stronger felt material. The advantage of needled felt is that in the option of using the resin material, it may be able to penetrate the fibrous layer, while during use the fibers are not easily pulled out of the resinous zone ensuring a strong connection.

[0043] The backing layer is preferably an air permeable layer for instance, a felt foam or textile layer, for instance a spacer fabric, for instance a 3D knitted fabric that may be stiffened with a binder or might be a reversed carpet layer similar to the surface layer.

[0044] Adjacent the backing layer on the surface facing away from the heating element additional layers can be used, for instance a foam layer, either slab foam or reaction injected foam, another fibrous layer, a thin nonwoven like a scrim or a closed or open film.

[0045] The fibrous layer may comprise staple fibres and or endless filaments, preferably polyester, like polyethylene terephthalate (PET), polyolefin, preferably polypropylene (PP) or polyethylene (PE), or poly-(lactic)-acid (PLA), polyamide, like polyamide 6 or polyamide 6-6, or mixtures thereof. The fibrous layer may also contain recycled shoddy fibres such as shoddy cotton, shoddy PET or other synthetic shoddy fibres or mixtures thereof. Preferably, the fibrous layer is polyester based.

[0046] In case at least the backing layer is air permeable, the floor part may contribute to the overall sound absorbing needs within the area used and/or enable the acoustic performance of the parts located underneath the floor part. Preferably, all layers are air permeable. For instance in the case the floor part according to the invention is a floor mat, the main flooring underneath might still contribute to the overall noise attenuation even with the heating element integrated in the covering floor mat due to the overall porous layout of the floor part.

[0047] Not only the acoustic attenuation benefits from the air permeability also transfer of the heat to the passenger is enhanced by a floor part that is overall air permeable. Advantageously the material used for the lower layers underneath the heating element have a higher thermal resistance than the top surface layer to enhance a heat flow in the direction of the passenger, for instance by increasing the content of materials with a higher thermal resistance and or by compacting the fibrous layer to increase the density of the material.

[0048] Surprisingly, by using a backing layer it was found that the heat transfer to the top was enhanced and the transfer to the lower layers was diminished, overall increasing the efficacy of the integrated heater in the floor part. In particular, the warm up time needed to create a heating effect on the surface of the floor part is reduced.

[0049] The fibres used may have a solid cross section but fibres with a hollow cross section might be preferred to make the fibrous layer lighter and/or loftier.

[0050] In case the fibrous layer is needled, a low amount of additional binder, preferably thermoplastic, might be added to the fibre blends to enhance the durability of the carpet after it is moulded. Preferably at least 0-50 percent of binder, for instance in the form of binder staple fibres are used. As binder a low melt polyester or polyolefin, with a melt point lower than that of the staple fibres just discussed can be used. Preferably, a polyester bi-component fibre is used for instance a fibre with a PET core and a Co-Polyester sheath, whereby only the sheath melts in order to achieve the bonding of the staple fibres.

[0051] In case the fibrous layer is not mechanically needled, a higher amount of binder might be mixed in the original fibres to enable the binding of the fibers between each other during moulding and thereby forming a bonded felt material. The binder content is in this case up to 50 percent in weight of binder, preferably between 10 and 40 percent in weight of binder, ever more preferred between 20 and 30 percent in weight of binder.

[0052] Preferably, the binder used in the fibrous layer is strong enough to bind the carrier layer of the heating element to the surface of the fibrous layer.

[0053] The fibrous layer might be a combination of frizzy hollow conjugate fibers with bi-component binder fibers and shoddy material, for instance cotton shoddy or polyester shoddy.

[0054] For example, the fibrous layer consists of 10 to 40 percent in weight of binder, 10 to 70 percent in weight of filler, preferably solid, fibers and 10 to 70 percent in weight of frizzy, preferably hollow, fibers and wherein the total amount adds to 100 percent by weight.

[0055] Preferably, a part of the filler material in the examples just given might be replaced by the recycled non-fibrous material. For instance, foam chips or scraps of floor parts might be mixed in the fibrous layer, preferably up to 30 percent, more preferably up to 25 percent by weight.

[0056] For example, the fibrous layer consists of 10 to 40 percent by weight of binder, 10 to 40 percent by weight of filler, preferably solid, fibers and 10 to 60 percent by weight of frizzy, preferably hollow, fibers and 10 to 50 percent by weight shredded foam pieces and wherein the total amount adds to 100 percent by weight.

[0057] Alternatively, the air permeable fibrous layer might be a carpet layer, for instance a tufted or nonwoven carpet layer as defined for the top surface layer. Putting a tufted layer facing downwards, placed against the main flooring part might enhance the anti-skidding performance of the floor mat.

[0058]

[0059] In case the floor part is a floor mat, the backing layer may be combined with a surface treatment or an additional layer on the surface destined to face the floor of the vehicle to include an anti-skidding function in this surface. For instance, the air permeable fibrous layer is a nonwoven carpet layer that may be flame treated to obtain a rough surface to enhance the anti-slip effect. Alternatively, a rough surface might be obtained by applying micronized rubber crumbles to the surface, or to use a thin course tuft layer to the back. Another alternative might be an additional natural or synthetic rubber layer including a spiked surface or protuberances, which is used as a back layer and will be hold by the engulfed area in addition.

[0060] Another alternative backing layer might be a tufted backing layer with a low stich-rate tufted backing whereby the tuft functions as anti-slip when in contact with a carpet flooring underneath the floor mat.

[0061] In addition, a combination of a thin polyurethane foam layer applied to the back of a fibrous layer might be used as a backing layer. As the main connection of the engulfed zone and the adjacent layers is obtained by the engulfing of the top surface layer and the fibrous layer, the thin foam layer only needs to be engulfed to obtain a nice finish of the part but not for maintaining the connection between the engulfed area and the rest of the floor part.

[0062] Preferably, the area weight of the fibrous layer is between 100 and 600 (g/m²), more preferably between 150 and 400 (g/m²).

[0063] Preferably, the airflow resistance of the fibrous layer is between 500 and 4000 Rayls. Preferably between 800 and 2500 Rayls.

[0064]

[0065] The air permeable fibrous layer might be lofty before forming of the part, as during the moulding of the floor part any thickness differences in the heating element might be hidden within the fibrous layer. Therefore, the surface would not show any deformation related to the integration of the heating element.

[0066] The backing layer might also be an open or closed cell foam layer, preferably a polyurethane foam layer. The foam layer might be either a slab foam layer or a reacting injection type foam layer.

[0067] Preferably, the heater might be placed on the backing layer with the heating circuit facing the backing layer. So that any thickness difference of the heating circuit, in particularly if a wire is used, is balanced out by the backing layer and not by the top surface layer, hence the wiring will not become visible in the surface layer.

[0068] Preferably, the overall thickness of all layers together is equal or close to the overall thickness of the means-for-connecting and the optional resinous layer or clasp on the top and lower surface of the means-for-connecting in plane with the surfaces of the floor mat, such that the connecting area is as flat as the floor mat itself without sticking out substantially.

[0069] In case the connector plug is also integrated within the periphery of the tail part, the thickness of the layers forming the floor part might be adapted to the height of the connector to obtain a flush or almost flush surface with the embedded connector.

[0070]

[0071] The facing layer might be anyone of a tufted carpet, a nonwoven carpet, a textile fabric, like a knitted fabric, a faux-suede fabric or a woven fabric, a nonwoven fabric, a leather or a closed cell foamed layer, a film, a foil or a flocked surface layer or any combination of such layers. Facing layers might be combined with a fibrous carrier layer to strengthen, stiffen or thicken the material, or to make it more durable. In addition, a soft padding might be used behind the facing layer, either one of a felt or foam material.

[0072] The materials used for the floor parts according to the invention can be from a virgin, reclaimed or recycled source.

[0073]

[0074] Depending on the facing layer, fibers might be used in the form of endless filaments, yarns or treads. Preferably, the fibers are made of polyester, like PET, PBT or PTT, polyamide, like PA6 or PA66 or polyolefin, like PP. The fibers can be made of virgin, reclaimed or recycled source.

[0075]

[0076] In one embodiment the facing layer is a nonwoven carpet facing layer may comprise a needle punched fibrous mat, for instance produced from fibrous webs made with a carding and cross lapping process. The thus formed web is reinforced and consolidated by the reciprocating action of barbed needles repeatedly penetrating the web so that the material becomes matted and decreases in thickness. The formed web might be a dilour.

[0077] The area weight of such a nonwoven carpet face layer used as standard in vehicles, are dependent on the area of use as well as the exclusivity of the car, normally in a range between 120 - 1500 g/m².

[0078] For a nonwoven carpet used as an aesthetic or decorative face layer the needle punched fibrous mat may be kept as a plain needle punch carpet or the plain needle punched carpet layer may be further enhanced by additional needling to give a more structured surface, this may be in the form of a ribbed, velour or random velour, also known as dilour. Other surface treatments to enhance the appearance without impairing the abrasion performance are also possible and fall in the scope of this disclosure. The surfaces might be cropped or uncropped. In addition, patterning using different heights of the pile or coloured yarns, or printed patterns on top of the surface layer might be used.

[0079]

[0080] In another embodiment the facing layer is a tufted carpet, it might be made of a BCF yarn tufted into a primary backing layer. Preferably, the BCF yarn and/or the primary backing is made from one of polyamide, polyester, for instance polyethylene-terephthalate (PET) or polybutylene-terephthalate (PBT) or polyolefin. The yarn might be a single yarn, twisted and/or heat set, and the thus formed floor part might be piece dyed as the last production step or the yarn might be dyed before producing the tufted surface. The area weight of the tufted surface layer might be depending on the purpose of the floor part between 200 and 2000 gsm.

[0081] Other types of tufted carpet layers known in the art may be used as a facing layer.

[0082]

[0083] An additional glue layer or glue layers might be used on the back surface of the face layer to glue the face layer to a surface of the heater element and or an adjacent layer. Preferably, a polyurethane based glue, a polyethylene based glue layer, like low density or high density polyethylene, or a polyester based glue might be used. [0084] Advantageously, a glue is chosen such that it increases the initial heat transfer from the heating element to the surface layer, for instance a polyester based glue. The time to heat from a cold state to a warm surface was reduced, while using a glue layer between the heating element and the cover layer.

[0085]

[0086] In case the face layer is a tufted carpet, the glue might be used to obtain a fiber lock and/or tuft lock within the surface layer as well as for binding the surface layer to the heating element and or to the carrier layer of the heating element.

[0087]

[0088] In case the heating element has no carrier layer, the glue might be used to bind the face layer to the fibrous layer, thereby embedding the heating element in the glue layer.

[0089]

[0090] By encapsulating any area where heater components meet cold wires, or a connector, with a resin or a clamping device, the design might prevent short circuits or electric short cuts, which might otherwise be caused by water ingress, deformation or even damage of the connection area.

[0091]

[0092] Eventually other electrical components like lighting elements, preferably LED type, might be included in the floor part and might use the same type of connecting area for the means-for-connecting the element to a suitable power supply.

[0093]

[0094] The socket and/or connector chosen can be dependent on the requirements of the carmaker, and if the floor part is used in aftermarket retrofitting of cars. The floor mat thus obtained can be easily connected to the available wire harness system of the car or alternatively to any other power supply available, like for instance the power supply used for electric powered adjustable seats. Due to the increase use of electronics in the passenger compartment of the car, it is now common to have connector boxes under the seats for instance. The place of the connector inside the mat can be adapted depending on the location of such a connector box within the car.

[0095] Preferably, the connector area is falls within the horizontal boundaries of the felt material. However, it might also stick out of the side of the floor part, but still be encapsulated by the thermoplastic resin according to the invention. Hence the connector as well as the adjacent area of connecting wires or cables within the carpet are protected by the over moulded area to obtain a more durable connection less prone to breaking due to mishandling the connecting area, for instance by standing on it, bending or pulling.

[0096]

[0097] Alternatively, the connector area falls within the horizontal boundaries of the carpet but the means for connecting are not exiting in the same plane but out of plane, preferably to the underside of the floor part. Preferably, a face layer covering the connecting zone visually hides the connecting zone.

[0098]

[0099] Preferably the thickness of the connector including the encapsulation or clasp is at least the same or larger than the thickness of the floor mat construction. The connector might fall within the thickness of the lower layers, whereby the carpet facing layer might be laminated after the encapsulation of the connector and might cover the connector. More preferably the connector is at least the thickness of all layers, whereby the surface of the encapsulation is in plane or above the carpet facing layer or alternatively in plane or above the layer underneath the carpet facing layer.

[0100] In case the surface of the over moulded resin or clasp is visible, it might be embellished with for instance ribs, logos or pictograms to increase the haptic and/or aesthetics of the encapsulation. By doing so the encapsulated connector might be more recognisable, and/or easy to handle during installation of the floor mat. Eventually a LED might be placed on the tail preferably within the encapsulation or the clasp area for functional control of the mat. [0101] Optional a glue layer between the carpet facing layer and the adjacent layer, and/or between the fibrous layer and an optional covering layer might be used.

[0102] A floor part with at least one fibrous layer and the encapsulated connector according to the invention might be used as an interior floor part for a vehicle. For instance as the already shown floor mat, for the front and/or the back seats, floor parts on or near the dash panel or underneath the dash panel, or as a mat for the frunk or for a front stowage compartment.

[0103]

[0104] Further benefits and advantages of the present invention will be explained with help of the drawings. Any features in the drawings and its description may be combined with the general background of the invention.

Brief description of drawings

[0105] Figure 1 Example of a floor part in the form of a heated floor mat with a tail part according to the invention.

[0106] Figure 2 Example of a floor part according to the invention with an alternative tail part.

[0107] Figure 3 is showing different possible solution for integrating the means-for-connecting in the tail part according to the invention.

[0108] Figure 4 is an alternative tail part solution according to the invention.

[0109] Figure 1 shows an example of a floor part according to the invention, with a main floor part 6, which might be attached to the automotive flooring with connectors 7. The automotive flooring might extend in a slope 5 underneath the seats of the car, hiding underneath the wire harness and or a power supply. The seats are indicated with the rails 4 they are connected too. The floor mat according to the invention has a main floor part 6 from which a tail 1 extends which can be placed against the slope 5 of the automotive flooring, for instance to an area under the seats. The tail comprises the means-for-connecting 2 the heating device of the floor mat to a power supply 3 and/or a control unit 3 for the heating device.

[0110] Figure 2 is showing an alternative floor part according to the invention with a floor part 1 is formed as a floor mat with an integrated heater in the form of a heating element 2 placed within the layers of the floor part. Such a carpet construction has at least a backing layer and a facing layer, for instance a carpet layer. The heater can be placed between these layers as a heating element alone or may be placed between the layers as a heating element on a carrier construction, for instance a nonwoven fleece, fabric or textile layer. The heating element might be connected to at least one of the adjacent layers to prevent the heating element from moving within the construction during production and/or use. Preferable all layers are laminated to each other thereby fixating the heater within the layers. Although the heater is shown on the drawing, in practise the heater is placed invisible between the layers. The heating element has at least two cables or wires coming from it, for the connection to the power supply. Other connecting wires might be available for instance for connecting to control units integrated in the heater within the floor part, or to be connected outside of the floor part. Wires might be grouped to have at least one connector or multiple connectors exiting the floor part, preferably the exit 4 is at the rim of the floor part, parallel to the horizontal boundaries of the floor part as shown in the example. However other direction might also be beneficial depending on the location and use of floor part within the vehicle.

[0111] In the floor part of the example formed as a floor mat, with F the front of the car is indicated, showing on the front side the tails needed for the pedal area. In the example, the connector is located opposite the pedal area, directed to the car seats. This is advantageous as most car models have a connecting box under the seat to connect any electronic device to a power system of the car.

[0112] The power cables or wires coming from the heater 2 are connected to a power connector for the connection to a suitable power supply (not shown); normally a male-female connector is used whereby preferably the male connector is placed within the floor part. However also alternative connector pairs might be used for instance based on magnetic connection. Depending on the connector used the actual connection of the cables and the connector might be inside the housing of the connector or before the housing of the connector. Preferably, both the connector and the cable connection are encapsulated in the thermoplastic resin 3 forming a connecting zone or area, further protecting the electric contacts and the connection. This prevent the actual connection from getting in contact with water or condense water, therefor decreasing corrosion or oxidation of the connection. At the same time, the connection is protected against tampering.

[0113] According to an embodiment, an injection moulding process encapsulated the connector including at least part of the connected cables such that the connector and cables are protected and at the same time attached to the surrounding layer or layers, in particularly to at least the fibrous layer. The area of the integrated connector 3 is arranged in a tail part, separated from the main surface of the mat by a small cut or indent 5, enabling a higher degree of movement of the tail. This will increase the handling of the floor mat during installing in, or taking out of the car, in particular plugging and unplugging of the floor mat is eased.

[0114]

[0115] A cut-out for the connector is preferable made before the lamination step, to prevent damage to the heater between the layers. The connector can be placed in the construction before the lamination step or is connected to the wire cables of the heating element after the lamination step.

[0116] Other appliances might be attached to the floor mat like for instance means for mounting the floor mat to the main floor, local embossed logos etc.

[0117] The floor mat might have a rubber insert for instance for placement of the pedal foot. The heating wire may be adapted to go around the area of the rubber insert, if needed.

[0118]

[0119] Figure 3 and 4 is showing different possible solutions for integrating the tail part comprising the means-for-connecting in the floor part according to the invention.

[0120] In all figures of 3 and 4, schematically a floor part 1 with a tail part is shown with the connecting zone 3 at least partially in the tail part and the exit of the means-for-connecting 2. With a dotted line, the overlap between the material of the adjacent layer and the penetration and/or engulfment of the resin material is shown. This overlapping area is the bonding zone between the resin and the adjacent layers, while the resin takes all the space available in the connecting zone accept for any area that belongs to a male or female connector plug.

[0121] In figure 3A the means of connecting are only partly placed within the tail area and are partly still within the main area of the floor part, while in figure B and C the means for connecting are outside the main part in a tail, whereby the tail in figure B is fully engulfed in a resin or alternatively might be formed by a clipped on casing solution, while in figure C the tail is formed by a combination of the means for connecting and at least some of the layers of the main floor part. Although in the version of figure 5C the connecting zone is outside of the boundaries of the trim the overlapping zone is still available with the rim of the adjacent material and therefore forming a solid connection to the mat.

[0122] An alternative to the tail of figure 5 B is a tail formed by the materials of the floor part. This has the advantage of a more flexible solution. The thus formed tail might be moulded together with the lamination step of the part in a 3 D shape, for instance out of the horizontal plane.

[0123] Figure 4 shows an alternative solution for the tail as an example. The tail part can extend from every angle and area from the main mat, to obtain a safe and secure connection between the heating device within the floor mat and the power supply.

[0124] The exit of the means for connecting is not necessary parallel to the horizontal boundaries of the floor part. For instance as a connecting zone that is directed to a power supply underneath the back surface of floor part. Such floor parts might for instance be used preferably for areas, which are not predominantly horizontal.

Claims

Claim 1 . Automotive floor part with integrated heating device comprising a main floor part comprising at least a backing layer, a facing layer and a heating element, whereby the heating element is between the facing layer and the air permeable layer and materially connected to the adjacent layers, and further comprising means-for-connecting the heating element to a power supply, characterised that at least part of the layer or layers of the main floor part are extended to form a tail part comprising the means-for-connecting.

Claim 2. Automotive floor part according to claim 1 , at least part of the material of the adjacent layer or layers forming the tail part are engulfed by a resin, such that the means-for-connecting are at least partly encapsulated in the resin and materially connected to the adjacent layers.

Claim 3. Automotive floor part according to claim 1 , whereby at least part of the material of the adjacent layer or layers forming the tail part are enclosed by a clasp such that the exit area of the means-for-connecting are secured.

Claim 4. Automotive floor part according to one of the preceding claims, whereby at least the backing layer and the facing layer forming the tail part comprise a cut-out for locating the exit area for the means-for-connecting and whereby the cut-out area including the means-for-connecting is encapsulated by the resin or enclosed by the clasp such that the means-for-connecting and the material of the adjacent layers are materially connected.

Claim 5. A floor part according to one of the preceding claims whereby the resin or the clasp is comprising a thermoset or a thermoplastic material, preferably the material is a polymer or copolymer selected from the group consisting of polyolefin, like polyethylene (PE) or polypropylene (PP) or ethylene propylene diene monomer (EPDM) or ethylene-octene (EO), polyester or thermoplastic elastomer of polyester (TPE-E), polyamide (PA) or thermoplastic elastomer of polyamide (TPE-A), polyoxymethylene POM, acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), Santoprene (TPV), styrene-butadiene copolymers (e.g. SBS), thermoplastic polyurethane (TPU), or a combination of these polymers.

Claim 6. A floor part according to one of the claims 1 to 5, whereby the resin is a thermoplastic hotmelt based material, preferably the hotmelt material is based on a polymer or copolymer of one of polyester, like polyethylene terephthalate (PET), polyolefin, like polypropylene (PP) or polyethylene (PE), poly lactic acid (PLA), polyamide, like polyamide 6 (PA6) or polyamide 6,6 (PA6,6) or mixtures thereof.

Claim 7. A floor part according to one of the preceding claims whereby the backing layer is at least one of a foam, felt layer or textile material, for instance a spacer fabric or a carpet layer.

Claim 8. A floor part according to one of the previous claims whereby the facing layer is at least one of a tufted carpet, a nonwoven carpet, a textile fabric, like a knitted fabric, a faux-suede fabric or a woven fabric, a nonwoven fabric, a leather or a closed cell foamed layer, a film, a foil, a thermoplastic polyurethane layer, or a flocked surface layer or any combination of such layers.

Claim 9. A floor part according to at least one of the preceding claims whereby the floor part further comprises additional layers at least one of a tufted carpet, nonwoven carpet, decorative layer, knit layer, a foam layer, either slab foam or reaction injected foam, another fibrous layer, a thin nonwoven like a scrim or a closed or open film or an anti-skidding layer.

Claim 10. A floor part according to claim 8, whereby the cut-out is at least in one additional layer, preferably in all layers.

Claim 11. A floor part according to one of the previous claims whereby at least a glue layer is used between the face layer and the heating element, and/or between the heating element and the backing layer.

Claim 12. A floor part according to claim 11 , whereby at least the glue layer between the face layer and the heating element is a polyurethane based glue, polyolefin based glue, preferably polyethylene or polypropylene, or a polyester based glue.

Claim 13. A floor part according to one of the preceding claims wherein the heating element is a metal based or a carbon based resistance element.

Claim 14. A floor part according to one of the preceding claims wherein the means-for-connecting comprises at least one of a cable, a plug, a connector, preferably comprising a magnet, connecting points where wires are connected, a control device, and a sensor device.

Claim 15. Use of the floor part according to one of the preceding claims as an interior part, like a floor mat, floor parts on or near the dash panel, or underneath the dash panel, a trunk floor part or a front stowing area floor part.